Tracker 4WD L4-2.0L VIN C (1999)
Synchronizer Hub: All Technical Service Bulletins
M/T - 4-3 Downshift/1-2 Upshift Gear Clash
File In Section: 07 - Transmission/Transaxle
Bulletin No.: 00-07-29-001
Date: September, 2000
Subject:
4-3 Downshift Gear Clash, 1-2 Upshift Gear Clash When Cold (Replace Affected Gear, Synchronizer Ring, Synchronizer Assembly and Transmission
Fluid)
Models:
1999-2000 Chevrolet Tracker with 5-Speed Manual Transmission (RPO M59)
Condition
Some customers may comment on gear clash under the following shift conditions:
^
Downshifting from 4th to 3rd gear
^
Upshifting from 1st to 2nd gear
This condition primarily occurs with a 4-3 gear downshift. However, careful diagnosis may reveal a 1-2 gear upshift condition, particularly when cold or
on an initial drive-away.
Correction
A new synchronizer spring service kit, P/N 91176347, has been released to reduce this condition. This kit includes two new springs for the 1-2
synchronizer (larger) and four springs for the 3-4 and 5-R synchronizer (smaller).
Complete manual transmission replacement is not necessary for this condition. This new spring kit and transmission fluid replacement should aid in
reducing this condition and improve overall shift performance and feel.
In order to properly correct the 4-3 gear clash condition, the following components must be replaced:
3rd Gear Clash
^
The 3rd gear, P/N 91175252
^
The 3rd gear synchronizer ring, P/N 96058173
^
The 3-4 gear synchronizer hub and sleeve, P/N 96068499
^
The 3-4 gear synchronizer hub inserts (3 required), P/N 96066873
4th Gear Clash
^
The 4th gear, P/N 91174539 (1 .6L) or 91174538 (2.0L)
^
The 4th gear synchronizer ring, P/N 96058173
^
The 3-4 gear synchronizer hub and sleeve, P/N 96068499
^
The 3-4 gear synchronizer hub inserts (3 required), P/N 96066873
1.
Install the above components along with new synchronizer springs in the 1-2, 3-4, and 5-R synchronizers.
2.
Reassemble the transmission and fill the transmission to the appropriate level with GM Synchromesh Transmission Fluid, P/N 12345349.
If after careful diagnosis you find a 1-2 gear clash condition, replace the following components:
^
The 2nd gear, P/N 96058162
^
The 2nd gear synchronizer ring, P/N 96058172
